Building structure



. May 2, 1944.

l. A; PALEY BUILDING STRUCTURE 4' Sheets-Sheet 1 Filed Jul# Y22. 1940 May 2, 1944. 1 A. PALEY BUILDING STRUCTURE Filed July 22. 1940 4 Sheets-Sheet 2 May 2 1944 A. PALEY 2,348,180

BUILDING STRUCTURE Filed July 22', 1940 4 sheets-sheet s @3 'N Jfw May 2, 1944- -L A.PALEY.

BUILDING STRUCTURE Filed Ju1yj22, 1940 4 `Sheets-Sheet 4 Patented May 2, 1944 OFFICE BUILDING STRUCTURE Lewis A. Paley, Bloomingdale, lil., assigner to United States 'Gypsum Company, Chicagmlli., -a corporation of Illinois Application July 22, 1940, Serlal No. 346,687

(Cl. 'l2-1) f 3 Claims.

This invention relates to building structures, and more particularly to iireproof buildings such as dwellings and the like which` are formed of quickly and easilyassembled units, most of which are preformed or prefabricated standardized parts which are adapted after assembly to provide a substantially integral structure of great strength with exceptional iireproof characteristics. The cost of material ordinarily used in building a small home is relatively high, irrespective of the type of material used, and the expense of skilled labor required in the erection of the average house is sometimes very great.

. Various attempts have been made to design poured cementitious structures such as small houses. However, with structures built of poured gypsum, great diiiiculty was experienced because the walls would not dry out for long periods, in fact, sometimes forseveral years, because of the affinity of the gypsum for the water in the mixture. The present invention provides a structure in which the gypsum elements are Another object is to provide a particularly emcient type of structure for the intersecting portions of walls wherein gypsum tiles having vertical registering core holes and staggered vertical ioints arev interlocked with each other and with the corner construction in such a manner as to form substantially a permanent integral construction. y

Another object is to provide a particular type of roof deck and floor construction which may, l

' of the character described in which the nishlargely precast and factory-dried; and such parts as are poured in the present structure'are formed of a particular type of high-strength gypsum which doesnot, present the drying outproblem of priorA structures, particularly as the poured gypsum is used only lin comparatively is reduced to a minimum.

Another object is to provide a wall structure for low cost homes which is made largely of gypsum and steel and which is entirely iireproof in so far as the finished structure is concerned,

except for such additional elements as might be desired for window and door casings and various trim elements, and in which even these elements may be of flreproof construction if desired.

Another object is to provide a type of wall in which low cost gypsum tiles may be used and suitably reinforced and-secured together in permarient relationship by means of interlocking and interengaging members and wherein alloithe elements co-operate to provide a rigid, substantial, and permanent low cost structure.

ing elements, 'such as wall coverings, Iloor coverings, shingles, and the like, may be nailed directly to the reproof structure without the use o1' wood or other combustible elements.

Further objects will be apparent from the specification and the appended claims.

In the'drawings:

Fig. 1- is a transverse sectional view through one embodiment of the invention and illustrates in detail a completed lowcost dwelling.

Fig. 2 is a fragmentary perspective view of a portion oi.' the wall structure and illustrates the relationship of the various elements, particularly the channel irons which may be used in#- terchangeably as sills or caps.

Fig. 3 is a fragmentary perspective view of the lower end of one oi the wire rafters.

Fig. 4 is a fragmentary perspective view partlally in section of the intersecting side walls and illustrates the method of starting a tier of the wall tile at a corner of the building with' l a tile section having a single therethrough.

Fig. 5 is similar to Fig. 4 but illustrates the method of starting a tier of the wall tile at a corner of the building with a tile section having two core holes therethrough. 'I'his view also illustrates the method of interlocking the blocks and corners of the structure.

Fig. 6 is va top view of a partially completed wall at a corner intersection, certain structural elements being shown in section.

vertical core hole Fig. '7 is an enlarged view of the eave andv4 rafter construction and illustrates its assemblyl with the side wall.

Fig. 8 is a transverse sectional view through the ceiling or floor joist and is taken on a line substantially corresponding to line 8 8 of Fig. 7.

2,348,1so l Y .structure with reinforcing studs therein. Conduits or pipes 8a (Fig. 4) may also extend through' registering core holes tosupply light,

water, and gas to the dwelling.

The poured gypsum, preferably used in the present invention is of the type disclosed and claimed in Patent No. 1,901,051, issued March 14, 1933, to Randel et al;, and for convenience is designated therein as alpha HDSUihland will be so designated herein. In accordance with the disclosure of the above noted patent, a very line substantially corresponding to line Il I.-I I of Figs. '7 and 10 and illustrates the method of" fastening the roof deck to the rafters.

Fig. 12 is a fragmentary perspective View of the laminated roof deck or floor deck element.

Referring to the drawings indetail, the embodiment illustrated comprises a foundation wall I which may be of any suitable structure or material, preferably of concrete. Transverse joists 2 are supported on the foundation walls in spaced relation in the usual manner, and additional support in the form of an intermediate transverse I-beam 3 may be provided if desired. The joists 2 may be of the type illustrated in Fig. 8 and are so constructed that floor members may be nailed thereto. These iloor joists are of a special construction particularly adapted to hold the nails by clamping them between steel elements. They are well known to the trade and will be described later. e l

The side walls of the structure are formed of low cost gypsum tiles ia such asshown particularly in Figs. 4, 5, and 6. These tiles are preferably about 30 inches long, 12 inches wide, and 4 inches thick, and are provided with three vertical core holes which may be substantially 21/2 inches in diameter and extend completely therethrough. 'I'he holes are properly spaced so that at least certain selected, equally spaced holes in an assembled wall will register in vertical alignment and enable the locating therein of metallic stud`ding. The tiles are preferably made without foam by a well known process which enables the production of nailable tile; that is, other elements of the building structure may be nailed directly to the tile, which is sulciently dense when madel without foam to provide good nail holding characteristics. i

In Fig. 4 eachalternate horizontal tier of the wall is started at the corner of-the building by a narrow vertical tile section 4 having a single core hole 5 therein so that, when assembled with full-sized tile 6 in the various tiers in assembled relation, the core holes 5 will be in vertical alignment with one of the outer core holes 5a in the adjacent tier of tile. The complete side wall may be assembled in this manner with the tile joints in staggered relation and with the usual layer of mortar 1 therebetween. The wall structure shown in Fig. 5 is substantially identical with that in Fig. 4 with the exception that the rst tier-of `tile is started adjacent the Acorlprepared gypsum 9 is poured into the holesas the wall is built up so that the channel irons or studding 0 are securely embedded therein and the entire wall becomes practically an integral having a low pouring consistency is produced which eliminates the drying out problem previously mentioned with reference to prior attempts to use poured gypsum in building structures. Also, this material may provide excellent nailholding characteristics, particularly when a small amount of ilber is added and the material prepared and used in a manner which will be described later in connection with the roof deck structure. This high-strength alpha gypsum has unique properties in that'its compressive and tensile strength equals or exceeds that of Portland cement, whereas its setting time is approximately that of ordinary plaster of Paris, viz., 15 to 30 minutes. The compressive strength of this product is very high and it has a pouring consistency of less than 50%.

Alpha gypsum is manufactured by treating lumps of gypsum rock having a diameter of l/2 inch to 2 inches in a closedI container with steam at 17 to 20 pounds gauge pressure. This steam calcination is carried on for 5 to 7 hours with a constant steam pressure and with a constant withdrawall of waterl of condensation obtained from the heating steam and also from the expelled water of crystallization. After calcination, the product isdried while maintaining at a temperature high enoughto prevent its rehydration, and the product is ground so that 85% or more passes through a 100 mesh screen. 'Ihe strength of set casts prepared from alpha gypsum increases as the amount of water mixedV with the calcined gypsum is decreased. All ordinarygypsum calcined according to present l methods requires the addition of more than consistency is the only cause of high strength oi 'ings' are provided for doors and windows.

rods il are of small. diameterv and are posithis product..

At the intersection of the walls to form a comer of the building, an angle strip I0 (Fig. 4) is secured to the tiles by means of nails Il', and reinforcing vertical rods 'I2 are positioned in the rectangular space formed ,by the walls and the angle iron. lThe alpha gypsum product previously mentionedis properly prepared and poured into this space, as shown at I3, to embed the reinforcing'rods and form a corner substantially integral with the side walls.

Between each horizontal tier of tile, a horlzontal reinforcing rod Il may be positioned as shown in Figs. 4 and 5, and these rods may be coextensive with the wall except where open- The tioned in the mortar Joints between the tile ascenso' and extend around the building, whereby y'they serve to prevent any tendency of the walls to bulge. The tiles adjacent the corners may also be connectedto the comer concrete structure by interlocking U-shaped members I6 and I1, which may be positioned in grooves I 8 and I8, respectively, formed in the tile, and these interlocking members may also be embedded in gypsum intheir respective grooves, which gypsum may be applied at the same time the studdings are embedded and the comers are poured. Ihe reinforcing rods I2 in the corner portions may be tied together by wire 'or other means, as shownY at |2a, to further reinforce the structure.

During the building of the side walls, suitable door and window openings such as shown at 2| (Fig. 1) may be provided, and these may be cased in any suitable well known manner by either wood or metal casings. Glass blocks I (Fig. 4) may also be embedded in the tile wall to provide interior lighting and a channel iron header |5a` is positioned above the glass block, as shown. Before starting to build'the side walls,

-channel iron sills 22 are laid on the foundation I and the tiles are vertically positioned therein to form the side walls. If desired, anchor bolts 23 may be secured in the foundation and extend upwardly into the gypsum corner sections |3 and be embedded therein, or they may extend into certain of the core holes in the blocks 6 and b'e embedded in gypsum therein.

An inverted channel iron 24 similar to the channel iron sill 22 just described is positioned along the top of the walll substantially as shown in Fig. 2. These channel irons or sills 22 and 24 may be provided with spaced slots 25 so that the studding' 8 may extend upwardly therethrough. J oists 26 are supported on the inverted channel iron 24 in suitable spaced relationship and each joist is secured to the associated upwardly extending studding 8 by means of bolts 21. The bolt holes in the studding are preferably larger than the ,bolts extending therethrough, so that the weight of the joists will rest onv the inverted channel iron 24. The joists 26 may be constructed substantially as illustrated in Fig. 8 and comprise a channel iron portion 28 having beads 29 in the web adjacent the edges. Angle' irons 38 are secured to the channel iron 28 in slightly spaced relation as shown, and these angle .irons are provided with complementary beads- 29a. These joists are of well known construction and are adapted to enable building elements to be nailed thereto by driving the nails into the space between the beads, whereby the nails are securely clamped between the elements. The studdings 8 extend upwardly any required distance above the ceiling joists 26, and the side wall tiers of tile are continued upwardly, but certain blocks are cut away around the joists, as required, and the interstices fille".A with poured gypsum. The end walls and end studding are extended upwardly to the roof line or as high as required.

Wire rafters 3| are secured to the upper ends of the studding 8. A portion of the lower end of one of the rafters 3| is shown in perspective in Fig. 3 and comprises upper chord wires 32, which are turned upwardly at their ends substantially at a right angle at 33. These upturnedV ends are engaged by the lower edges of roof .plaster 5| applied thereto.

curely fastened to the rafters. The rafters are provided with lower chord wires 34 and a zigzag web wire 35, which latter is welded at its crestsv 36 to the corresponding chord wires. This wire structure provides a. skeleton I-beamwhich is of inexpensive construction and great strength.

Each of the rafters is provided with fan L- shaped bracket plate 31 (Figs. 7 and 9), andV this bracket is secured to the web wires, preferably by welding, as shown at 38. The rafter ifs-.pivf oted to the studding 6 by means of a pivotb'foltJB` so that the angle of the rafters may ber adjustedA as required. The bracket 31 is also provided with va slot 48 on a radius from the pivot bolt, Aas, shown by dotted lines in Fig. 7,. and, after proper adjustment of the rafters, they are secured to the studding by means of bolts 4| extending through the slots 40. The upper ends of co-operating rafters( ar secured together by means of wire ties 42, and all of the rafters are secured together by means of an elongated angle plate 43 and bolts 44. The bolts may extend between the chord wires of the respective rafters and clamp thereto by means of suitable washers.45. The rafters may also besecured together by means of intermediateangle irons 46 which are bolted to the rafters in the same manner by means of bolts 41.

The attic walls or second floor walls may be formed by suitable positioning vertical studdings 48 and horizontal beams 48, and these studdings and beams may be of the same wire construction as the rafters just described and may be tied together and to the rafters 3| by. wire ties 48a. Gypsum lath 50 may be secured to these studdings in the usual manner and a coating of is 'supported on the joists 26 and may be of substantially the same construction as the roof deck which will be described later.

The lower floor, which is supported on the `joists 2, may be of the usual Awell known metaledged gypsum slabs 53 and secured by nails driven into the joists 2, which may be' of the same construction as previously described and illustrated in Fig. 8. These floors .may have linoleum 53a applied thereto or any other suit-l able covering, and the usual baseboards 54 may be applied to the wall. These baseboards are preferably of metal construction adapted toenclose a wiring'conduit 54a. The interior partitions 55 may be formed of the usual three-inch gypsumpartition tiles in the well known manner, and these tiles may have .a surface coating 56 of plaster or other suitable material.`

A portion lof the roof deck is lillustrated in perspective in Fig. 12 and comprises two layers of paper-covered gypsum boards 51 and 58 which tain the boards in place .until they are later seare adhered together by means of a layer of high-strength alpha gypsum 59 having a sheet of expanded metal. 68 embedded therein. The top gypsum board 58 is preferablS1 about onehalf inch thick, and the bottom board about three-eighths inch thick, so that the embedded expanded metal 60 will be below the neutral axis of the slab, thereby making a materially stronger roof deck with the use of a comparatively small amount of material. The lower exposed surface Aof the gypsum board 61 is provided with a heat The attic floor 52` .nails 58.

4 tained by means of theiupturned ends of the rafter. They are also bolted to the rafter brackets 31 by bolts 51a. The expanded metal 5% is .then laid on the roof and will give a foothold for the workman while he applies a thin coating of the high-strength alpha gypsum. This coating need be only suiiiciently thick to embed the expanded metal.

The upper boards 58 are then applied' to the gypsum coating and pressed thereon-by nailingor the like, and the high adhesive characteristics of the alpha gypsum form 2a are preferably provided with a coating of the asphalt. The exterior surfaces of the tiles asphalt primer paint prior to erection to impart a very strong roof deck which" is practically v monolithic. The expanded metal 60 isv preferably bent over the peak of the rof so as to provide a strong peak construction.'

The previously described high-strength alpha gypsum 59, in which the expanded metal is embedded, is used not only to provide great strength in the roof deck, but also for the reason that it provides exceptionally good nail holding characteristics. Ordinary gypsum board may be'used for the layers 51 and 58.` However, such boards do not provide good'nail holding qualities. It has been found, however, that, by the use of the alpha gypsum containing a small proportion of paper fiber, excellent nail holding characteristics may be obtained andthe alpha gypsum is not cracked or broken. It will be obvious that the main object is to provide a high-strength calcined gypsum layer, through which nails may be driven without cracking or breaking the layer temporary weather resistance to the tile and to 'provide a better bond between the asphalt emulsion and'the tile.

The interior of the wall is provided with perforated furring channels 55a. to which insulating gypsum boards 10 (Fig. '1) are secured 'as by nailing through the furring strips into the tiles 2a to'provide an air space 1l. The gypsum board 1|) is provided on its inner surface with a bright metal foil coating 12 which acts as a vapor seal and as a heat insulating medium. Insteadof the boards 10, a finishv coat ofgypsum plaster may be applied to the inside of tiles and the Acore holes are poured full of gypsum cement to embed the studs. The succeeding courses of tiles 2a are laid up by threading each alterand in which the layer, and in fact the entire roof deck, -is materially strengthened by the expanded metal. V'Ihe nail holding qualities of the roof deck may be materially improved by using gypsum' boards 51 and 58 having avdense gypsum core made without theluse of foam or other density reducing agents. However, the highstrength gypsum layer 59 through which the nails 59a extend, as shown in Fig. 12, provides exceptional nail holding power which is sufficient for all ordinary purposes. After the roof deck is applied as shown att! (Figs. '1 and 10), it may further be secured to the rafters by means of staples 62 which are passed around one of the chord wires of the associated rafter and driven diagonally into the roof deck as shown. Conventional shingles 53 may then be applied to the roof and nailed to the roof deck in the usual manner. As previously stated, the attic iiooris illustrated as being constructed in the same manner as the roof deck just described, and suitable ceiling gypsum or other boards 51 may be nailed to the joists 26` by means of The cornices preferably comprise a sheet metal box-like member. (Figs. 1 and '1) having a roof flange 65 which may be nailedl to the roof deck and a wall flange 55 which may similarly be nailed to the side' walls. A sheet 4metal gutter 64a may be secured to the cornice 54 by welding or other suitable means.

The exterior finish of the walls may be 0f any,A suitable material such as asphalt shingles, as-

bestos-cement shingles or siding, roll brick siding, or even wooden clap boards. However, in

nate tile over the protruding ends of studs 8 which extend through the registering core holes. rl'fhe rafters, joists, and other elements of the structure are then assembled. When the construction of the building .is temporarily discontinued, as at-night, the inside surfaces of tiles 2a g may be protected from a shower by loosely attaching a strip of metal'along the top of the Wall, the strip extending inwardly and downwardly as an eave, shielding the inside of the tile wall from rain.

The present invention provides many-advantages for.1 ow cost building construction in that the building is reproof and substantially monolithic and is easily and inexpensively constructed. It is also moistureproof and formed of materials which are largelyprecast and factory-dried. The assembledv elements are made substantially integral by interlocking high-strength gypsum molded on thejob. The roof pitch is variable, y

and the w'alls, oors, and roof decks are provided with exceptional nail holding characteristics. The structure is suitable not only for dwellings," but for industrial buildings of various kinds.

It is intended, of course, that the' invention should not be limited to the lspecific embodiment or embodiments disclosed herein, since modi- Y flcationsmay be made, and it is contemplated,

the preferred embodiment, granule-coated roll roofing 69 is adhered to the wall with asphalt emulsion supplemented by a -few nails driven into the ti1es. This roofing is preferably provided with surface granules of white crushed porcelain, and these granules are painted with exterior cement or other suitable paint to provide, any .tint desired and to prevent any discoloration of thewhite granules by bleeding of therefore, by the appended claims to cover any such modifications as fall within the true spirit and scope of this invention.

Having thus described this invention, what is -claimed and desired to be' secured by Letters Patent is:

l. A nailable floor or roof deck slab comprising two gypsum boards adhesively secured together by a layer consisting essentially of hard, dense,

- strong calcium sulfate`resulting from the setting of low consistency gypsum, and a sheet of expanded metal embedded in said layer.

2. A nailable iioor or roof deck slab comprising two gypsum boards adhesivelysecured together by a layer consisting essentially of hard', vdense, strong calcium sulfate resulting from the setting of low consistency gypsum, and a sheet of expanded metal embedded in said layer. said layer being only sufii'ciently thick to embed the expanded .metaL and the -upper one of said boards being materially thicker than the other so that said layer and embedded expanded metal 5 ','are'r'emote from the neutral axis of said slab.

of gypsum-board on a permanent support formingpart of said structure. superimposing a. sheet of large mesh expanded metal on said gypsum boardapplying a cementitious layer of material comprising essentially low consistency gypsum of only suiiicient thickness to embed said expanded metal therein, and pressing a. second layer of plaster board snugly on said gypsum.

. 1 LEWIS A. PALEY.

summon@ oF CORRECTION. Patent No. 2,5'LL8,180. may 2,- 1 9L|l;.

mas A. PALEY.

It is hereby certified that error g'ppears in the printed .specification of the above numbered patent requirin correction as follows: Page 1, first column, line 55, for partically read practica11y; page Ll., second co1- umn, linel, strike out "2a are preferably provided with acoating of" and insert the same fterfti'les" in line 2; line 25, for "titles" read tiles; and that the said Letters' Patent should be readwith this correction therein that the same may conform to lthe record of the case in the Patent ffice.

signed and sealed uns 5rd day of octber, A'. D. 19m.

Leslie Frazer (Seal) Acting Commissioner of Patents. 

